U.S. patent number 6,122,937 [Application Number 09/171,370] was granted by the patent office on 2000-09-26 for process for producing three-dimensional knitted fabrics and textile material thus produced.
This patent grant is currently assigned to Recaro GmbH & Co.. Invention is credited to Friedrich Roell.
United States Patent |
6,122,937 |
Roell |
September 26, 2000 |
Process for producing three-dimensional knitted fabrics and textile
material thus produced
Abstract
The present invention relates to a method of producing a
three-dimensional knit, i.e. a knit whose area is shaped spatially.
In accordance with the invention a homogeneously tough
three-dimensional knit structure is achieved when loops in specific
portions are widened and/or narrowed, this widening/narrowing of
the loops being done at many locations arranged distributed
homogeneously over the area to be formed three-dimensionally. In
the same way a three-dimensional knit may be produced in which the
knitting needles are inactivated at least in part over at least one
course in the portion to be shaped and later reactivated whilst in
the other portions full knitting is continued.
Inventors: |
Roell; Friedrich (Biberach,
DE) |
Assignee: |
Recaro GmbH & Co.
(Kirchheim-Teck, DE)
|
Family
ID: |
7792088 |
Appl.
No.: |
09/171,370 |
Filed: |
October 16, 1998 |
PCT
Filed: |
April 18, 1997 |
PCT No.: |
PCT/DE97/00792 |
371
Date: |
March 22, 1999 |
102(e)
Date: |
March 22, 1999 |
PCT
Pub. No.: |
WO97/40221 |
PCT
Pub. Date: |
October 30, 1997 |
Foreign Application Priority Data
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Apr 18, 1996 [DE] |
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196 16 005 |
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Current U.S.
Class: |
66/70; 66/76 |
Current CPC
Class: |
D04B
1/22 (20130101); D04B 1/108 (20130101); D10B
2403/032 (20130101) |
Current International
Class: |
D04B
1/22 (20060101); D04B 007/10 () |
Field of
Search: |
;66/64,70,71,73,76,77,61,75.1 |
Foreign Patent Documents
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631470 |
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Dec 1927 |
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FR |
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562751 |
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Oct 1932 |
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DE |
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3937406 |
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May 1991 |
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DE |
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469998 |
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Aug 1937 |
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GB |
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2206609 |
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Jan 1989 |
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GB |
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Primary Examiner: Worrell; Danny
Attorney, Agent or Firm: Smith-Hill and Bedell
Claims
What is claimed is:
1. A method of producing a knit by creating loops, said method
comprising:
(a) knitting a first portion of the knit by creating loops,
(b) knitting a second portion of the knit by creating widening or
narrowing loops at a first plurality of deformation regions, the
deformation regions of said first plurality being distributed over
the second portion of the knit with a substantially uniform
density, and
(c) knitting a third portion of the knit by creating widening or
narrowing loops at a second plurality of deformation regions, the
deformation regions of said second plurality being distributed over
the third portion of the knit with a substantially uniform
density,
wherein the density of deformation regions in the third portion of
the knit is different from the density of deformation regions in
the second portion of the knit and wherein each deformation region
has a width no greater than ten loops.
2. A method according to claim 1, wherein step (b) comprises
creating widening loops in first and second wales, whereby the
first and second wales are split and form, respectively, a first
pair of wales and a second pair of wales, and subsequently creating
narrowing loops which recombine the first pair of wales and the
second pair of wales respectively, there being a fully knitted wale
between the first pair of wales and the second pair of wales.
3. A method according to claim 1, employing twin needles for
knitting and selecting a first number of active needles for each
twin needle in step (a) and a second number of active needles for
each twin needle in step (b), and wherein the first number is
different from the second number.
4. A method according to claim 1, employing a flat knitting machine
with twin needles, wherein both needles of the twin needle are used
for knitting in step (b) and only one needle of the twin needle is
used for knitting in step (a).
5. A method according to claim 1, wherein step (b) comprises
creating widening loops and subsequently creating narrowing
loops.
6. A method of producing a knit having a multiplicity of courses
employing a knitting machine having a plurality of needles each of
which can be deactivated and reactivated, said method
comprising,
(a) knitting a first portion of the knit with all the needles in
the active state,
(b) knitting a second portion of the knit with selected needles in
the inactive state over at least one course, and
(c) knitting a third portion of the knit with all the needles in
the active state,
and wherein step (b) includes deactivating the selected needles and
subsequently reactivating the selected needles and wherein
deactivating and reactivating of the selected needles in the second
portion of the knit is effected at a plurality of points that are
distributed over the second portion of the knit and are
substantially equispaced with respect to the courses of the
knit.
7. A method according to claim 6, wherein in step (b) the selected
needles remain in the inactive state over up to thirty courses.
8. A method according to claim 6, wherein step (b) includes
repeatedly deactivating and subsequently reactivating the selected
needles and wherein in each repetition the selected needles remain
inactive over from one to thirty courses.
9. A method according to claim 8, wherein on successive
repetitions, the number of needles that remain inactive varies.
10. A method of producing a knit having a multiplicity of courses
employing a knitting machine having a plurality of needles each of
which can be deactivated and reactivated, said method
comprising:
(a) knitting a first portion of the knit by creating loops,
(b) knitting a second portion of the knit by creating widening or
narrowing loops at a first plurality of deformation regions, the
deformation regions of said first plurality being distributed over
the second portion of the knit with a substantially uniform
density, and
(c) knitting a third portion of the knit by creating widening or
narrowing loops at a second plurality of deformation regions, the
deformation regions of the second plurality being distributed over
the third portion of the knit with a substantially uniform
density,
wherein the density of deformation regions in the third portion of
the knit is different from the density of deformation regions in
the second portion of the knit and wherein each deformation region
has a width no greater than ten loops, and
(d) knitting a fourth portion of the knit with all the needles in
the active state,
(e) knitting a fifth portion of the knit with selected needles in
the inactive state over at least one course, and
(f) knitting a sixth portion of the knit with all the needles in
the active state,
and wherein step (e) includes deactivating the selected needles and
subsequently reactivating the selected needles and wherein
deactivating and reactivating of the selected needles in the fifth
portion of the knit is effected at a plurality of points that are
distributed over the fifth portion of the knit and are
substantially equispaced with respect to the courses of the knit.
Description
The invention relates to a method of producing a three-dimensional
knit, i.e. a knit whose surface area is shaped spatially, as is the
case of e.g. balaclava helmets or sock heels, shaping being
achieved by accepted practice in loops being widened and/or
narrowed in specific portions of the knit.
It is in the marginal portion of such widening or narrowing that
inhomogeneities materialize due especially to the normal, i.e. not
knitted three-dimensionally, knit being tensioned or deformed in
the marginal portion of the three-dimensionally knitted area.
Accordingly, these marginal portions represent a weakened zone
having the tendency to open up when exposed to mechanical
stress.
It is thus the object of the present invention to provide a
three-dimensional knit which is relatively insensitive all over to
mechanical stresses.
In accordance with the invention widening or narrowing the loops is
no longer done in a single defined portion, but at many locations
preferably distributed homogeneously in the shaping area. In this
way shaping is integrated homogeneously in the knit, i.e.
excessively stressed margins no longer occur in the marginal
portion of a closely defined shaping area which tend to break
prematurely.
The art in accordance with the invention permits production of all
possible shapes such as e.g. spherical or dished shapes without
e.g. as in the conventional fashioning technique a line existing
within which all loops are reduced, resulting in the knit being
subjected to particular stresses in the region of this line. Due to
the invention, widening or narrowing or inactivating needles is
distributed over the complete portion to be shaped so that the
deformation of the knit no longer occurs along a line, it instead
being homogeneously distributed over the complete knit.
Furthermore, the deformation at each and every widening or
narrowing location or needle inactivating/activating is no longer
so pronounced since due to the plurality of locations
widening/narrowing/inactivation becomes less at each location, i.e.
the deformation of the knit at any widening/narrowing/inactivation
location is less than in prior art in which all
widening/narrowing/inactivation needed for shaping was done at only
a single or a few locations.
These locations as cited above are now homogeneously distributed by
the invention over the portion to be shaped, this distribution
being intended to be as even, i.e. homogeneous as possible. The
distribution may be achieved regularly, i.e. controlled so that all
widening/narrowing/inactivation locations are spaced away from each
other more or less evenly. However, these locations may also be
distributed statistically over the portion to be shaped, thus
avoiding the creation of all and any texture possibly consistituing
a design break point.
The degree of deformation is preferably controlled via the density,
i.e. the mutual spacing of the locations where
widening/narrowing/inactivation occurs. Should heavy deformation be
desired, then these locations are arranged in a higher density than
in portions in which less deformation is wanted. In this way
homogeneous textile pieces may be produced comprising portions less
and more deformed as desired, thus enabling homogeneous knits to be
produced in any desired shape.
A basic distinction is made between two ways of producing
three-dimensional textile structures. For one, a three-dimensional
shape is achieved by widening and/or narrowing the loops in several
portions of the knit, whereby the number of widened/narrowed or
split/unified loops per location should not be excessive, e.g. not
amount to more than ten loops. Widening several loops within the
knit at several locations produces a bulge in the knit at the
widening locations. Narrowing the loops in the knit at a plurality
of locations causes the knit to pucker in this portion, again
producing a bulged portion. Widening and narrowing may be combined
as desired to achieve the desired shapes.
Another way of producing three-dimensional knits consists of
rendering needles inactive in specific portions of the knit whilst
knitting is continued with the needles in other portions. By later
activating these inactivated needles, e.g. after one or more
courses a puckering of the knit in this inactivated portion is
achieved which in turn may be made use of to achieve specific
shapes. When, for instance, in knitting the needles are made
inactive in the marginal portions of the flat knitting machine, and
this inactivation repeated on a spacing of a few courses differing
in width, a spherical configuration is achieved having a highly
homogeneous structure. In this case too, inactivating the needles
should be done only over a few courses to avoid excessively
deforming the knit at any one location. Furthermore, the width
(needle number) of inactivating may be alternatingly varied so that
also by these means a distribution of the deformed locations may be
achieved in the shaping portion, these locations being positioned
at point s at which an inactivated portion adjoins a fully knitted
portion.
Both of the principles as cited above for producing geometric knits
may be put to use with the method in accordance with the invention
in that widening/narrowing the loops, on the one hand, or
inactivating needles, on the other, is distributed to many
locations in the shaping portion. In any case, a more homogeneous
structure of the three-dimensional knit is achieved, on the one
hand, which in turn has enhanced mechanical properties.
A distributed widening/narrowing of the loops within the knit may
be achieved to advantage by using twin needles. For example, an
alternating knit may be done with the A and B needles of the twin
needles, resulting in a loop count corresponding to twice the
number of active twin needles or conventional needles. When a
reduction in the loop count is desired, knitting is continued only
with one of the A or B needles of the twin needle. This results in
the loop count being reduced to half for the same width of the
active portion of the needle bed. This reduction may also be
achieved in other steps when the reduction to one of the two
needles of the twin needle is not implemented for every twin needle
but e.g. only to ever second such needle. Likewise, an increase in
the loop count may be achieved by changing from knitting with one
of the two needles of the twin needle to knitting with both
needles, the two needles of the twin needle then being activated
successively.
The invention will now be described by way of an example as
illustrated schematically in the drawing in which:
FIG. 1 is a construction for knitting a spherical knit by
inactivating needles in the marginal portion of the knit;
FIG. 2 is an illustration of a bulged portion achieved by widening
and narrowing loops in one portion, and
FIG. 3 is a construction of a bulged portion achieved by widening
and narrowing loops in accordance with the invention.
Referring now to FIG. 1 there is illustrated a construction for
producing a roughly spherical knit, the actual knitted textile area
10 being evident from this Figure. Shaping the textile is achieved
by inactivating needles partially or completely within a portion b
on both sides of the textile area 10 so that in this portion
knitting is not done over one or more needle rows. In subsequent
reactivation of the needles the loops are then joined to the loops
last knitted, i.e. specific portions of the courses are simply
missing during the time in which activation of the needles in the
marginal portion b of the knit 10 is lacking. Accordingly, the
courses before and after the missing portion are simply knitted
together, as a result of which the knit in this portion is puckered
corresponding to the number of non-knitted courses. The points at
which a deformation occurs in this arrangement are the points 11.
At these points 11 the inactivated portions adjoin the fully
knitted portions, this being the reason why preferably the width of
the inactivated portion, i.e. the number of inactivated needles is
continuously varied so that also the deformation points 11 are
homogeneously distributed within the shaping portion b. In this way
a defined structuring of the reduction is avoided which in turn
would involve a weakening of the knit. The mutual spacing of the
inactivations 12, 14, 16 is relatively constant so that the
deformation points 11 exhibit a more or less homogeneous spacing
also in the interlooping direction.
In the construction as shown in FIG. 1 the needles are inactivated
in a first short portion 12, covering for example only 20 needles.
In a later portion, i.e. a couple of courses further, the loops are
inactivated in a portion 14 extending over the full width b of the
shaped portion. Inactivation in this case would involve e.g. 60
needles. Again a couple of courses later, the needles are activated
over a width 13 located between the two widths as cited above, e.g.
for 40 needles. The deformation points 11 are thus homogeneously
distributed over the deformation width b. The inactivated portions
12, 14, 16 are always alternated with fully knitted portions 18 in
which the knit is produced over the full width, resulting
in more or less equispacing of the points 21 in the interlooping
direction. Running through the middle of the knit 10 is a portion
20 which is fully knitted, whilst furthermore outwards a portion 22
extends in which the knit already comprises non-knitted courses at
a spacing of several courses. These non-knitted portions widen in
the outward direction as is easily appreciated from the drawing.
When now envisaging the knitted portions 18 being joined to each
other at their top and bottom edges, it will readily be appreciated
that the knit as illustrated in FIG. 1 is roughly spherical in
shape. Each inactivation 12, 14, 16 runs in the knit over two
courses in sequence. It is, of course, just as possible to directly
attach various inactivated portions 12, 14, 16 to each other
without any fully knitted portions inbetween in wanting to achieve
stronger shaping. The degree of shaping is set by the spacing, i.e.
the sequence of the inactivations and the width of the inactivation
portions 12, 14, 16. Thus, the wider the inactivation portions and
inactivation sequence, the stronger is also the shaping.
Whilst FIG. 1 illustrates a method for producing three-dimensional
knit structures by inactivating needles, FIGS. 2 and 3 show a
knitting method in which a three-dimensional shape is produced by
widening or narrowing the loops. FIG. 2 illustrates a method in
which three-dimensionally shaping the knit is done in a defined
portion 30 where, namely, in a first stage 32 a loop is doubled,
the loop being split into two loops so that instead of a single
wale two wales now exist. At the location 34 the two wales are
again split into two wales each so that now four wales exist which
at the location 36 are yet again split up into eight wales. It is
at this location that the portion 30 is widest. At the location 40
two loops each are puckered into a single loop, i.e. reduced, as a
result of which after the location 40 only four wales exist. At the
locations 42 and 44 a further reduction is made so that in the end
only a single wale is again present. In the portion 46 about the
three-dimensionally shaped portion 30 the knit is subjected to an
increased mechanical stress due to the deformation in this marginal
portion. This deformation involves premature fatigue, wear and tear
of the material or greater susceptibility to mechanical
stressing.
To get round this disadvantage the widening in accordance with the
invention is not done in a portion 30, as shown in FIG. 2, but at
five different locations 50, 52, 54, 56, 58 at each of which a loop
is split up into two loops and subsequently recombined into a
single loop. The splitting duration for the five locations differs,
so that a homogeneous distribution of the widening/narrowing
locations within the knit exists. Furthermore, between the
widening/narrowing location 50, 52, 54, 56, 58 fully knitted wales
60 are arranged serving to enhance the homogenity of the knit
throughout the complete shaped portion.
It will readily be appreciated from comparing the prior art knit
method to the new knit method that shaping the knit is
substantially more homogeneous than in prior art and that such a
knit is very much more resistant to mechanical stresses and
premature material fatigue. In addition to this, the geometry of
the three-dimensionally shaped portion may be better controlled by
the invention, i.e. via the spacing of the locations 50, 52, 54,
56, 58 and via the widening/narrowing length at each single
location 50, 52, 54, 56, 58. In the present example, the longest
widening is undertaken in the middle portion, i.e. the portion most
bulged, whereas in the adjoining locations 52, 56 the widening is
not so long and in the marginal locations 50, 58 the widening is
only relatively short, here, for instance, the widening/splitting
extending over one to ten courses.
The present invention is thus suitable for producing all possible
geometric shapes such as spheres, cones and all kinds of regularly
and irregularly shaped bulges. Both widening/narrowing the loops
and partially inactivating the needles in a course may be done in
an unequal spacing and to a differing extent. It may furthermore be
done controlled or statistically to achieve as high a homogenity as
possible. Care is to be taken, however, in the distribution of
these locations and in the distribution of the extent of
widening/narrowing/inactivation so that, in all, a more or less
consistent shaping of the knit is achieved over the full area.
The two basic techniques of widening/narrowing, on the one hand,
and fashioning, on the other, may, of course be optionally combined
with each other.
* * * * *